Protective glove with multiple layer construction

ABSTRACT

A multi-layer protective glove fabric comprises a base cloth layer, a second stretchable cloth layer overlying the base layer, a third latex layer coated on the base layer and a fourth wax layer over the third latex layer to prevent the latex coating layer from blooming. The method of manufacturing a protective glove with this multi-layer construction includes (1) heating a fabric layer at a first elevated temperature; (2) applying a viscous latex spreading compound over a surface of the fabric layer at a second, lower elevated temperature, to prevent the latex from penetrating the fabric layer but ensuring its adhesion to the fabric layer; (3) applying wax over the latex at least at the first elevated temperature, to prevent the latex from blooming; (4) adhering an opposed surface of the fabric layer to a second fabric layer to form the multi-layer fabric and (5) forming the multi-layer fabric into a glove.

FIELD OF THE INVENTION

This invention relates to a multi-layer cloth work glove having latexand wax coatings thereover and a method of making the same. Morespecifically, the thin latex coating adheres to but does not saturatethe cloth layers and the wax layer prevents chemical blooming of thelatex, to provide a comfortable, longer lasting work glove.

BACKGROUND OF THE INVENTION

Work gloves, such as the type used for carpentry, gardening or farmwork, are typically formed from a knitted fabric made of cotton orpolyester material. Some improvement in grip and wear is achieved byreinforcing portions of the glove fabric with plastic in a dot patternor by application of a vinyl coating.

Prior known latex coating processes typically use multiple rollers ordoctor knives, however, and are unable to produce a smooth, thin coatingof uniform thickness. Other conventional pressurized spraying processesdo not ensure uniform thickness or good adhesion between the latexcoating and fabric layers. Known latex coated gloves also do not includea wax layer applied over the latex and thus are subject to chemicalblooming (i.e., unattractive whitening).

SUMMARY OF THE INVENTION

Accordingly, it is a primary object of the subject invention to providea multi-layer cloth work glove formed of thin and stretchable coatedfabric that when sewn into gloves, is preferable for hand protectionduring most light-duty applications where tactile sensitivity anddexterity are important and acts as an effective barrier to many commonmild liquids as well as pointed or sharp objects, such as insect bites,and keeps hands clean, dry and safe.

It is another primary object of the subject invention to provide amulti-layer cloth work glove including an outer surface coated withnatural latex to improve the a glove's tensile strength, elongation andresistance to abrasions and cuts.

Another primary object of the subject invention is to provide a latexcoated multi-layer work glove that further includes a layer of wax overthe latex which acts as an effective barrier to atmospheric ozone andthus minimizes premature aging (blooming) of the latex.

Still another primary object of the subject invention is to provide alatex coated multi-layer work glove that includes a layer of wax overthe latex, which provides a shine on the glove's outer surface and thusenhances the attractiveness of the glove.

Still another object of the subject invention is to provide amulti-layer work glove formed of two layers of fabric to provide acomfortable and stretchable glove for many light-duty applications.

Yet another object of the subject invention is to provide a multi-layerwork glove including a bottom or inner layer of soft knitted jerseypolyester fabric having a fleeced bottom surface to provide goodperspiration absorption for long wearing comfort as well as effectiveinsulation against cool outdoor weather.

Yet another object of the subject invention is to provide a multi-layerwork glove including a second knitted interlock cotton fabric layersandwiched between the latex layer and the fleeced fabric layer to serveas a reinforcing substratum and enhance the stretchability of the glove.

These objects are attained by providing a multi-layer protective glovefabric comprising a base cloth layer, a second stretchable cloth layeroverlying the base layer, a third latex layer coated on the base layerand a fourth wax layer over the third latex layer to prevent the latexcoating layer from blooming.

These objects may also be attained by providing a method ofmanufacturing a protective work glove with a multi-layer construction.The method includes (1) heating a fabric layer at a first elevatedtemperature; (2) applying a viscous latex spreading compound over asurface of the fabric layer at a second, lower elevated temperature, toprevent the latex from penetrating the fabric layer but ensuring itsadhesion to the fabric layer; (3) applying wax over the latex at leastat the first elevated temperature, to prevent the latex from blooming;(4) adhering an opposed surface of the fabric layer to a second fabriclayer to form a multi-layer fabric and (5) forming the multi-layerfabric into a glove.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side elevational view of the latex coating machine inaccordance with the present invention with portions thereof broken awayto show details with clarity;

FIG. 2 is a top plan view of the latex coating machine of FIG. 1;

FIG. 3 is an enlarged, top plan view of the latex coating section of thelatex coating machine of FIG. 1 with the knife adjuster removed forclarity;

FIG. 4 is an elevational view of the latex coating section of the latexcoating machine of FIG. 1;

FIG. 5 is an enlarged side view of the latex coating section of thelatex coating machine of FIG. 1;

FIG. 6 is a side view of the wax spraying machine in accordance with thepresent invention; and

FIG. 7 is a top plan view of the wax spraying machine of FIG. 6;

FIG. 8 is a side view of the laminating machine showing the latex coatedfabric being adhered to the polyester fabric;

FIG. 9 is a perspective view of the latex coated fabric in accordancewith the present invention, but without the wax layer thereover;

FIG. 10 is a perspective view of the multi-layer fabric of the presentinvention;

FIG. 11 is a top plan view of a multi-layer, protective work glove inaccordance with the present invention; and

FIG. 12 is a bottom view of the glove of FIG. 11.

DETAILED DESCRIPTION

Protective work glove 10, as shown in FIGS. 11 and 12, is partly formedof the multi-layer fabric 12 of FIG. 10, in accordance with the presentinvention. Specifically, the glove 10 is formed with the multi-layerfabric 12 at the palm 20, first finger 22, thumb 24 and the palm side ofthe remaining fingers portion 26. This multi-layer fabric 12 provides anabsorbent and durable coated fabric for fabrication into high-touch andhigh-stretch protective gloves, such as glove 10, which are comfortableand stretchable for wearing in many light-duty applications.

The backside of the remaining fingers portion 28 is preferably formed ofa dual layer fabric, comprising the base layer 34 and second layer 42 asfurther discussed below. Of course, this unreinforced portion of theglove may be formed of any other type of fabric as desired.

The fabric 12 includes a base layer 34 of knitted jersey polyesterfabric, preferably approximately 99 g/sq. m in density and 0.52 mm inthickness. Its bottom side 36 is fleeced and non-coated and thus offersperspiration absorption for longer wearing comfort and effectiveinsulation in cool outdoor weather.

The top side 38 of the base layer 34 is laminated to a second layer 42of knitted, stretchable interlock cotton fabric at its bottom side. Thissecond layer 42 is preferably approximately 100 g/sq. m in density and0.31 mm in thickness. The second cotton layer 42 is sandwiched betweenthe fleeced polyester base layer 34 and a third latex layer 50, to serveas a reinforcing substratum and enhance the stretchability of the latexcoating 50.

The second layer's top side 46 is evenly coated with the third layer 50of smooth, vulcanized, natural latex, as discussed in detail below. Thelatex is approximately 200 g/sq. m in density and 0.2 mm in thickness(plus or minus 10%). Natural latex, such as this, outperforms mostsynthetic lattices in tensile strength, elongation and resistanceagainst abrasion and cuts.

A fourth or top layer 54 of spray-on paraffin wax coating forms a thin,protective layer over the third latex layer 50. This layer 54 serves asan effective barrier against atmospheric ozone and hence minimizespremature aging of the latex. In addition, the waxy finish leaves anattractive lasting shine on the top surface of the fabric 12. As shown,fabric 12 is formed into glove 10 as discussed above. It mayalternatively be formed into other articles requiring similar reinforcedstretchability and comfort.

Latex Coating Process

The latex coating 50 is applied over the top surface 46 of the secondcotton layer 42 via latex coating machine 70, shown in FIGS. 1 and 2.The cotton layer 42 of fabric is fed from a rolled bale into a heatedoven 72 via take up roller 73 on a conveyor belt 74 travelling at acontrolled speed of preferably 1.6 m/min. The conveyor belt 74 is drivenby transmission chain 75. Oven 72 subjects the fabric 42 to about 20 mof direct heating by wet steam up to a temperature of 60° C. The directsteam heating is carefully controlled so as not to destruct the delicatecellulose structure of the cotton yarn, which may otherwise promotestrike-through of the latex coating 50. On the other hand, the surfacetension of condensed vapor on the fabric at elevated temperature enablesfast deposition of an even and smooth latex coating 50.

The oven temperature is reduced from 60° C. to 45° C. before the cottonfabric 42 passes into the latex spreading section 76 of coating machine70, as seen in detail in FIGS. 3-5. Rollers 84 move the fabric 42 intothe latex coating section 76 and onto a feeding platform 85 of conveyingbelt 86. The brush wheel assembly 88 transfers the fabric 42 over thefeeding platform 85 via the opposed brush wheels 90 and transmission ortransfer wheels 92, to adjust the fabric tension for coating. The upperconveyor transmission device 96 drives the upper belt 74. Latexspreading section 76 is preferably 1500 mm by 150 mm and includes latexdepositing limiter 78 for discharging (or pouring) and maintaining aconstant mass of 7 kg of latex on the top surface 46 of the cottonfabric 42, which is preferably travelling at a constant speed of 1.6m/min.

At the exit area 80 of this spreading section 76, a doctor knife 82controls the uniform spreading of the latex coating thickness. Thedoctor knife 82 is adjustable by opposed adjusters 94.

At this latex coating section 76, the gravity force is translated intooptimum pressure action on the latex coating mass to penetrate into thefabric without having the undesirable side effect of striking through,or penetrating the cotton fabric 42. On the other hand, the heatedcotton fabric 42 at 45° C. is sufficient to coagulate the latex coatingto ensure a secured adhesion between the latex coating and the cottonfabric layer 42. Thus this coating section 76 provides the optimumconditions for the desired coating requirements, the combination ofcontrolled gravity force and elevated temperature.

The coated fabric is then conveyed to an upper drying oven 100 where itis first subjected to about 10 m of indirect heating up to 60° C. beforean additional 10 m of heating up to 100° C. It is finally subjected toabout 20 m of heating up to 120° C. to ensure complete drying andvulcanization.

The latex coated fabric is cooled by air cooler 102 on exit from theoven 100, prior to removing it to the wax coating machine 110 forspraying with emulsified wax.

Wax Coating Process

The wax layer 54 is applied over the latex layer 50 via wax coatingmachine 110, shown in FIGS. 6 and 7. The latex coated fabric passes overrollers 112 and is sprayed with a layer of diluted emulsified wax (apreferred mixing ratio of water: wax is 17:1) with pressurized guns 114onto the latex surface 50 of the coated fabric at a travelling speed ofpreferably approximately 5 m/min. at a temperature of 60° C. Anadditional layer of emulsified wax in higher concentration (thepreferred mixing ratio of water: wax is 8:1) is sprayed in a similar wayby guns 116 at a conveying speed of approximately 5 m/min. and at atemperature of 80° C. After spraying, the fabric 104, as seen in FIG. 9,is subject to air cooling and drying before being baled for laminationto the base, polyester layer 34.

Fabric Lamination

Fabric 104 is laminated to the top surface 38 of base polyester layer 34via laminating machine 120, shown in FIG. 8. Laminating machine 120includes glue reservoir 122 and glue take up roller 124 which applies anadhesive layer onto the bottom, non-coated surface 44 of the cottonfabric layer 42 of fabric 104. The adhesive is preferably industrialgrade resin-agent type glue. Cotton fabric layer 42, at its bottomsurface 44, is then compressed at 126 with the top surface 38 of thebase polyester layer 34. The multi-layer fabric 10 is conveyed viatransport rollers 130 through the oven 134 of glue drying drum 132 (inthe direction of the arrows) for drying at 80° C. prior to being aircooled and rolled for fabrication as desired, such as into glove 12.

Having thus described the invention, what is claimed as new and desiredto be secured by Letters Patent is as follows:
 1. A multi-layerprotective glove fabric, comprising: a base cloth layer; a secondstretchable cloth layer overlying said base layer; a third layer oflatex coated on said second cloth layer; and a fourth wax layer oversaid third latex layer to prevent said latex coating layer fromblooming.
 2. A glove fabric as claimed in claim 1 wherein said baselayer is knitted jersey polyester fabric having a fleeced bottom sidefor contact with a glove wearer's skin.
 3. A glove fabric as claimed inclaim 1 wherein said second layer is knitted interlock cotton fabric. 4.A glove fabric as claimed in claim 1 wherein said third layer is smooth,vulcanized natural latex.
 5. A glove fabric as claimed in claim 4wherein said third layer is about 2 mm in thickness.
 6. A glove fabricas claimed in claim 1 wherein said fourth layer is a thin layer ofspray-on paraffin wax.
 7. A glove fabric as claimed in claim 1 whereinsaid third latex layer and said fourth wax layer are co-extensive andcover said first and second layers at a palm, first finger, thumb andpalm side of the remaining fingers portion of said glove.